FIELD OF THE INVENTION

The present application relates to a method for recovering material from a used consumable item. In particular, the embodiments are directed to consumable items having wearing elements and a body. In particular, the application relates to methods for separating materials for reuse in new consumable items and to methods for supplying such consumable items.

BACKGROUND OF THE INVENTION

Many consumable items are readily disposed of because they are cheap to make, they wear out or they harbour bacteria if kept for too long. They are often manufactured using several dissimilar materials and non-biodegradable materials. As such, the recovery and recycling of materials from disposed consumable items can be complicated and expensive. The disposal of consumable items in ever-increasing numbers adds to global pollution problems, causing damage to ecosystems and the environment.

For items such as toothbrushes and other personal hygiene products, reusing the items or reducing usage can be impractical and undesirable, so (limited) recycling is often the only way to minimise their impact on the environment. Some existing consumable items have parts which are biodegradable or are formed partly from recycled materials. However, true separation and recovery of mixed materials for recycling are generally not possible for such products, resulting in continued waste and a need for virgin materials (e.g. plastics) in manufacturing.

In order to reduce overall consumption of materials and energy, in some industries recycling processes are used as part of a wider closed recycling loop in which complex formed products (e.g. engines) are re-manufactured without being totally broken down. In the case of simple consumable items, this is generally not considered desirable or practical, particularly if there are hygiene concerns.

SUMMARY OF THE INVENTION

Aspects of the invention are set out in the independent claims and preferable features are set out in the dependent claims.

There is described herein a method of recovering material from a toothbrush or toothbrush head comprising bristles made from a first material type and a body made from a second material type, the method comprising the steps of: extracting the bristles from the body; processing the bristles in a first recycling process and/or processing the body in a second recycling process; and providing material from at least one of the first and second recycling processes to a process for forming a new item. The method allows toothbrushes or toothbrush heads with bristles made from a different material to that of the body to be more fully and directly recycled, minimising the environmental impact of the production and disposal of such items. By processing at least one of the bristles and the body in a first and second recycling process respectively, and by using the material from at least one of the body and the bristles in a new item, it is possible to provide recycled products more efficiently with minimal waste. By extracting the bristles from the body, separation of the first and second material types is improved, especially compared to existing methods such as cutting off the part of the body attached to the bristles (such as the toothbrush head) and only recycling part of the body, or leaving some or all of the bristles embedded in or attached to the body, which can result in low grade material yielded from recycling. A toothbrush head generally refers to an electric toothbrush head, such as a removable and/or replaceable head that can be fixed to an electric toothbrush handle and drive mechanism.

While some examples of the method may be used for recovering material from new or un-used toothbrushes or toothbrush heads, such as those which would otherwise be discarded (for example due to manufacturing defects or excess supply), the method is normally used for recovering material from used toothbrushes or used toothbrush heads.

In some examples, the method may comprise both the steps of processing the bristles in a first recycling process and processing the body in a second recycling process. This can further increase the amount of material recovered by the method by recycling both the body and bristle materials, thus further reducing waste and environmental damage.

The method may further comprise the step of bio-degrading the body. The body may be bio-degraded if the body is not processed in the second recycling process. This can allow material from the body to be disposed of in a manner that nonetheless reduces environmental damage by avoiding, for example, landfill disposal. Where the body is biodegraded, the second material type may be biodegradable, such as wood, bamboo or a biodegradable plastic.

The method may further comprise the step of burning the body. The body may be burned if the body is not processed in the second recycling process. This can reduce environmental damage associated with alternative manners of disposal, such as landfill. The method may further comprise the step of capturing energy released when burning the body. Capturing the energy released when burning the body allows energy to be recovered from the toothbrush or toothbrush head, reducing the net energy expenditure in producing said toothbrush or toothbrush head. The captured energy may be provided to a local network or grid network as electrical energy. The captured energy may be stored, for example electrochemically, mechanically or thermally.

The new item may be a new consumable item. The new item may be a new toothbrush or toothbrush head.

There is also described herein a method for extracting bristles from a body of a toothbrush or toothbrush head, the method comprising the steps of: securing the toothbrush or toothbrush head in a moveable cradle; clamping the bristles in a clamp mechanism; softening a region of the body local to the bristles; and applying a force to the cradle to move the body to separate the body from the bristles.

There is also described herein an apparatus for recovering material from a toothbrush or toothbrush head having bristles made from a first material type and body made from a second material type, the apparatus comprising: means for extracting the bristles from the body; means for processing the bristles in a first recycling process and/or means for processing the body in a second recycling process; and means for providing material from at least one of the first and second recycling processes to a process for forming a new item.

The means for extracting the bristles from the body may comprise a moveable cradle having a slot, the cradle configured to receive the toothbrush or toothbrush head and the slot configured to receive the bristles.

The cradle and slot can allow the toothbrush to be secured in the apparatus by using a friction fit, removing the need for any further securing mechanisms. The bristles can be exposed via the slot so that they can be clamped.

The means for extracting the bristles from the body may comprise a heating element configured to heat a region of the body local to the bristles.

The heating element can allow the region of the body local to the bristles to be softened, facilitating the extraction of the bristles from the body.

There is described herein an apparatus for extracting bristles from the body of a toothbrush or toothbrush head, the apparatus comprising: a moveable cradle having a slot, the cradle configured to receive the toothbrush or toothbrush head and the slot configured to receive the bristles; a clamp mechanism configured to clamp the bristles; and a heating element configured to heat a region of the body local to the bristles.

The methods described herein are not necessarily limited to toothbrushes and there is described herein a method of recovering material from a used consumable item comprising one or more wearing elements made from a first material type and a body made from a second material type, the method comprising the steps of: extracting the wearing elements from the body; processing the wearing elements in a first recycling process; processing the body in a second recycling process; and providing material from at least one of the first and second recycling processes to a process for forming a new consumable item.

The method allows consumable items comprising wearing elements and a body made of separate materials to be more fully and directly recycled, minimising the environmental impact of the production and disposal of such items. By using the material from at least one of the body and wearing element(s) in a new consumable item, it is possible to provide recycled products more efficiently with minimal waste. By extracting the wearing elements from the body, separation of the first and second material types is improved, especially compared to existing methods such as cutting off the part of the body attached to wearing elements and only recycling part of the body, or leaving some or all of the wearing elements embedded in or attached to the body, which can result in low grade material yielded from recycling.

The term “consumable item” refers to items which, by virtue of being used, require replacing wholly or partially at regular or irregular intervals. The item is typically a consumer item, but may be for industrial or clinical use instead. Examples of consumable items are brushes having bristles (such as toothbrushes, hairbrushes, washing up brushes or dustpan brushes) and razors.

Although many examples described herein relate to forming a “new consumable item”, in the alternative the example methods and apparatuses may instead be used to form a new item that is not consumable. Examples of such new items include drainage pipes, packaging, components for mechanical, electrical or medical devices, furniture and any other product which directly or indirectly requires material of the same type(s) as that recovered from the methods described herein for its manufacture or formation.

Preferably the new consumable item also comprises one or more wearing elements made from the first material type and a body made from the second material type. The new consumable item may be the same type or form of consumable item as the used consumable item.

In some embodiments, the method further comprises providing material from both the first and second recycling processes to the process for forming the new consumable item.

During usage, the wearing elements typically wear down, for example by becoming blunt, deformed, damaged, inhibited and/or otherwise unusable. The wearing elements may be fibres, filaments or elongate bodies with substantially prismatic structures, such as bristles or razor blades. In the case of having bristles, the consumable item may be a brush, such as a toothbrush, broom, dishwashing brush, bottle brush, toilet brush or hairbrush. The method may further comprise the step of decontaminating the used consumable item prior to extracting the wearing elements from the body the used consumable item is washed with a washing agent, preferably water. Additionally, or alternatively, the used consumable item is heated at a temperature of preferably at least around 80°C for at least around 1 minute. This step allows bacteria or microbes present in the used consumable item to be removed.

The consumable item may further comprise one or more anchors coupled to the wearing elements for securing the wearing elements to the body, and the method may further comprise separating the anchors from the wearing elements. The anchors may be made of metal, preferably a copper alloy such as nickel silver. Separating the anchors from the wearing elements may comprise the step of electrostatically separating the anchors from the wearing elements. Clear separation between the anchors and bristles may be achieved since metals, and in particular copper alloys, are good conductors of electricity. The method may further comprise the step of disassembling the one or more clusters prior to separating the anchors from the wearing elements, wherein disassembling preferably comprises cutting at least a portion of the wearing elements. Alternatively, disassembling may comprise separating each cluster into individual wearing elements or smaller clusters of wearing elements, such that the anchors are not constrained by the wearing elements once the wearing elements and the anchors are separated from the body. This can allow the anchors to separate freely from the wearing elements once removed from the body, reducing the risk that anchors require excessive force in order to be separated from the wearing elements and that an electrostatic separator is unable to achieve complete separation. Alternatively, the wearing elements may be secured to the body by inserting their ends into or through holes disposed in the body and melting and/or sealing the ends of the wearing elements against the body. Alternatively, the wearing elements may be secured to the body by inserting their ends into holes disposed in the body and applying a compacting force to the region of the body local to the wearing elements in order to crimp the holes against the wearing elements. Both of these alternative methods for securing the wearing elements to the body remove the need for metal anchor wires, thus reducing the number of components and different materials present in the consumable items. Alternatively, the wearing elements may be secured to the body by one or more staples, and the method may further comprise separating the staples from the wearing elements.

The step of extracting the wearing elements from the body may comprise the steps of clamping the wearing elements, softening the body at least in a region local to the wearing elements, and applying a force to move the body and/or the wearing elements to separate the body from the wearing elements. Here, separating means creating a complete separation between and totally decoupling the body and the wearing elements. Softening the body allows the wearing elements to be wholly removed without leaving substantial broken or residual parts of the wearing elements remaining in the body. Applying a force to move the wearing elements may require the force to be aligned with the wearing elements such that there is a minimal moment applied to the softened body, which could otherwise result in unwanted bending and an incomplete separation of the wearing elements from the body. Alternatively, applying a force to move the body may allow for simplified apparatus, for example the body may be held by a single movable clamp throughout the recycling process, minimising the need for other movable parts.

Softening is preferably performed by applying heat. Heat may be applied by radiation, e.g. by infrared heating. Heat may be provided by immersing the body (or a part of the body) in a hot fluid, such as hot water or steam. The heat may be applied to a temperature of at least around 80°C, preferably between around 100°C and 130°C. Generally the heat will be applied at less than 140°C.. In other embodiments (for example where the body material is wood or bamboo), heating may be to lower temperatures. For example to around between 60°C and 95°C, preferably at least 70°C or at least 75°C and/or preferably less than 90°C or 85°C, for example around 80°C. Where the second material is a plastic, heating by radiation may be preferred. Where the second material is a wood or bamboo, heating by immersing in a hot fluid may be preferred.

It may be desirable not to soften at least part of the body (generally a part that is not directly coupled to the wearing element(s), for example, where the wearing elements are coupled or attached to a first end of the body, a second (e.g. opposite) end may not be softened in the softening process. This may improve handling, such as providing a part of the body to be gripped during the separation step.

The wearing elements may be made entirely from the first material type and the body may be made entirely from the second material type. This further facilitates recycling of the material types once the bristles are removed from the body. The second material type may comprise a mixture of two or more materials.

A major portion of the wearing element material from the first recycling process and/or a major portion of the body material from the second recycling process may be provided directly to the process for forming a new consumable item. This makes the overall recycling process more efficient compared to using indirect recycled materials.

The first material type may be a meltable material, such as a thermoplastic. The first material type may be a polymer, preferably nylon or polyester. The first material type may be plant based, for example nylon may be derived from castor bean oil. Nylon has good strength and durability when used for wearing elements such as toothbrush bristles. The method may further comprise the step of melting the wearing elements together into one or more clusters prior to extracting the wearing elements from the body. Melting the wearing elements together makes the removal of the wearing elements from the body and subsequent handling of removed wearing elements easier.

The second material type may be a meltable material, such as a thermoplastic. The second material type may be a polymer, preferably polyhydroxyalkanoate, PHA. The second material type may comprise a composite blend of two or more polymers, preferably polybutylene succinate, PBS, and a polyhydroxyalkanoate, PHA such as poly(3- hydroxybutyrate-co-3-hydroxyvalerate), PHBV. Other possible blends may include PHBV and poly(butylene adipate-co-terephthalate), PBAT, or PHBV and poly(ethylene glycol), PEG. The first material type may have a higher melting temperature than the second material type. Advantageously, the body can be softened without affecting the wearing elements, such as bristles. Softening the body may comprise the step of applying heat until at least the region local to the wearing elements reaches a temperature of at least 85°C, preferably between around 100°C and 130°C, but no more than 140°C.

The second material type may be wood or bamboo. Softening the body may comprise the step of soaking at least the region local to the wearing elements in a liquid or gas. Preferably the liquid or gas is heated to a temperature of at least 60°C, for example between 80°C and 100°C. The liquid/gas is preferably water or an alcoholic solution preferably with an alcohol concentration of around 50% v/v. This allows a body made from a material which is not meltable, such as wood or bamboo, to be softened prior to removing the bristles. The region local to the wearing elements may be submerged in the liquid for a predetermined length of time, wherein the length of time is preferably at least around 1 hour. Alternatively, the region local to the wearing elements may be covered with the liquid, for example by spraying, for a predetermined length of time, wherein the length of time is at least around one hour, preferably at least around two hours.

At least one of the first material type and the second material type may be bio degradable at ambient temperatures and/or under anaerobic conditions. Bio-degradable material types include polylactic acid thermoplastic (PLA) and modified forms of PLA. PLA and modified forms thereof will break down in anaerobic conditions, typically in an anaerobic digestion process under raised temperatures. Bio-degradability at ambient temperatures minimises the environmental impact of any consumable items which are not recycled, and biodegradability under anaerobic conditions allows excess material not required for producing new consumable items to be digested to natural substances and any greenhouse gases captured in the process. At least one of the first material type and the second material type may bio-degrade under aerobic conditions and/or in fresh or salt water. Such material types may include PHA, PHBV, PBAT and PBS. This allows the consumable items or components thereof to be bio-degraded using domestic compost equipment.

The first recycling process may comprise the steps of melting the wearing elements to form melted material and extruding the melted material to form extruded material and optionally then pelletizing the extruded material. The extruded material may not need to go through the pelletizing step to make a new item, product or component(s) for a new product. For example nylon may be repeatedly extruded to form thin nylon, sometimes referred to as nylon 'monofilament', which does not need to be pelletized to form a new item or component. This can be particularly applicable to forming new bristles. The extruded material may be used to form new wearing elements, such as bristles, without pelletizing the material. The first recycling process may optionally comprise decontaminating prior to melting. Decontaminating ensures that contaminants such as non-recyclable materials, microbes and bacteria are removed from the wearing elements regardless of the pelletizing method suited to the first material type: for example, the melting temperature of nylon may mean that melting alone may not remove all impurities.

The second recycling process may comprise the steps of shredding the body, melting the body to form melted material, extruding the melted material to form extruded material, and pelletizing the extruded material. Again, the second recycling process may optionally include decontaminating to help reduce contaminants in the body material.

The process for forming a new consumable item may comprise the step of using material recovered by the first recycling process to form one or more wearing elements of the new consumable item preferably by melting and extruding and/or using material recovered by the second recycling process to form a body of the new consumable item preferably by melting and injection moulding. Advantageously, this creates a closed recycling loop for the consumable items, minimising the environmental impact and waste generated. The material recovered by the second recycling process may comprise a composite blend of the two or more polymers. The material recovered by the second recycling process may be mixed with virgin material of the second material type to form the body of the new consumable item. The material recovered by the second recycling process may be anaerobically digested to produce natural substances such as methane and carbon dioxide which may be captured. The natural substances may be used as feedstock to produce new material of the second material type, such as PHA. Alternatively, captured natural substances such as methane may be used for other purposes such as biofuel or feedstock in other chemical processes such as hydrogen production.

Alternatively, the process for forming a new consumable item may comprise the step of using wearing elements received directly from the step of separating the anchors from the wearing elements to form one or more wearing elements of the new consumable item preferably by melting and extruding the wearing elements, and/or using material recovered by the second recycling process to form a body of the new consumable item preferably by melting and/or injection moulding. Advantageously, this removes the need for the wearing elements to be processed, such as being pelletized, before forming new wearing elements.

Additionally or alternatively, the method may comprise the step of providing material from at least one of the first and second recycling processes to a manufacturing process. This can allow material recovered from toothbrushes to be used to manufacture other items or products in the same or other industries requiring such materials, providing more efficient recycling of materials such as polymers and reducing waste and environmental damage. The manufacturing process may comprise the step of using material recovered from the first recycling process to form one or more items partially or wholly made from the first material type. The manufacturing process may comprise the step of using material recovered from the second recycling process to form one or more items partially or wholly made from the second material type. The items may be reusable or single-use items. The items may be intended for use over an extended period of time, or over a short period of time. Thus, in some embodiments the new items are consumable, but in other embodiments they are not necessarily consumable. The items may include pipework such as underground drainage pipes, packaging, tools, appliances or any other item requiring the first or second material types directly or indirectly as part of their manufacturing process.

The method may further comprise the step of receiving the used consumable item from a user. The method may further comprise the step of returning the new consumable item to a user. The new consumable item may be packaged in an inner sleeve held in a container, wherein the inner sleeve is recyclable and/or compostable. The inner sleeve may be made from a material which is recyclable, bio-degradable and/or compostable, such as potato starch or paper. The inner sleeve keeps new consumable items clean and free from contamination prior to use, while being recyclable and/or compostable reduces the environmental impact of disposing of the sleeve.

The wearing elements may comprise a plurality of bristles. The body may comprise a handle. The used consumable item (and preferably the new consumable item) may be a toothbrush, or a toothbrush head for use with an electric toothbrush. The wearing element(s) may comprise a razor blade or a plurality of razor blades. The used consumable item (and preferably the new consumable item) may be a razor, or a razor head for use with a manual or electric razor.

The process for forming a new consumable item may be performed at the same site as at least one of the first and second recycling processes, preferably in a substantially continuous process. This reduces the energy consumption and amount of waste generated when transporting materials, personnel and other goods between different sites, thus reducing the overall environmental impact of the material recovery method. The method may be performed at a single site, preferably in a substantially continuous process. Similarly, performing the whole method at a single site helps to minimise the environmental impact.

According to another aspect, the present invention provides packaging for transporting a consumable, recyclable item, wherein: the packaging is arrangeable in a first configuration and a second configuration; wherein in each of the first configuration and the second configuration the packaging is releasably closed for securing the used or new consumable item inside the packaging; wherein in the first configuration a first indicia-bearing surface of the packaging is visible and a second indicia-bearing surface of the packaging is hidden from view; and wherein in the second configuration the first indicia-bearing surface is hidden from view and the second indicia-bearing surface is visible.

The first and second configurations facilitate the easy sending of consumable items to a second address or location, such as returning used consumable items to the original sender, and reduces waste packaging. This is particularly useful for consumable items that require periodic replacement, since old, used items can be returned in the same box new items were previously provided in, and then new, replacement items can be sent to the user in the same box. Thus a single box can be used for multiple trips.

The packaging may be made from cardboard, preferably recycled cardboard. Advantageously, if the packaging is a recycled material, the energy consumption and waste are reduced compared to that for packaging made from non-recycled virgin materials. Moreover, cardboard is readily biodegradable, meaning disposal of such packaging does not cause long term environmental pollution. The packaging may be arranged to hold more than one consumable item, preferably at least four consumable items. This allows for more cost and energy-efficient sending and receiving of consumable items, and may provide convenience for the user. The number of items that can be held in the packaging may be dependent on the weight of the consumable items. A first hinged flap may be arranged uppermost in the first configuration, and a second hinged flap may be arranged uppermost in the second configuration, wherein in each of the first configuration and second configuration the first hinged flap and the second hinged flap overlap at least partially, but preferably substantially completely.. The first and second hinged flaps may comprise the first and second indicia-bearing surfaces respectively.

The packaging may further comprise one or more retaining features for retaining the or each new or used consumable item inside the packaging. The or each retaining feature may comprise a slot for receiving an end of the consumable item, wherein the slot is disposed in an internal face of the packaging, and wherein an end of the consumable item opposite to the end received in the slot is held against a second internal face of the packaging with a friction fit, wherein the first internal face and the second internal face are substantially opposed. The packaging may further comprise a first securing mechanism for keeping the packaging closed in the first configuration, and a second securing mechanism for keeping the packaging closed in the second configuration. At least one of the securing mechanisms may comprise one or more tabs and one or more slots, wherein at least one of the tabs is configured to releasably fit into at least one of the slots. At least one of the securing mechanisms may comprise one or more tabs for operating at least one of the securing mechanisms. The securing mechanisms ensure the packaging can be fastened shut in both the first and second configurations, allowing consumable items to be transported securely in each configuration. The securing mechanisms may operate via mechanical, adhesive, magnetic, hook-and-loop and/or electrostatic means. Advantageously, mechanical securing mechanisms can be made using cardboard alone, requiring no additional materials. Alternatively, adhesive, magnetic, hook-and-loop and electrostatic mechanisms may only require surficial contact between two regions, providing a simpler construction. Adhesive and hook-and-loop mechanisms may provide the strongest resistance to opening, although adhesive means may only be used a limited number of times.

The packaging may be constructed by folding a single sheet of material. This reduces the number and amount of materials required to produce the packaging, and may facilitate simpler manufacturing and transport.

The or each new consumable item may be individually enclosed in an inner sleeve, wherein the or each inner sleeve is recyclable and/or compostable, and wherein the inner sleeve is contained in the packaging.

According to another aspect, the present invention provides apparatus for recovering material from a used consumable item having one or more wearing elements made from a first material type and a body made from a second material type, the apparatus comprising: means for extracting the wearing elements from the body; means for processing the wearing elements in a first recycling process; means for processing the body in a second recycling process; and means for providing material from at least one of the first and second recycling processes to a process for forming a new consumable item.

The means for extracting the wearing elements from the body may comprise a clamping mechanism configured to receive and/or clamp the wearing elements, softening apparatus for softening the body at least in a region local to the wearing elements, and a separation mechanism operable to apply a force to move the body and/or the wearing elements to separate the body from the wearing elements.

The apparatus may further comprise means for decontaminating the used consumable item comprising a washing element and a heater. The washing element may be configured to spray, hose or bathe the used consumable item with a washing agent, preferably comprising water. The heater may be configured to heat the used consumable item and/or the washing agent to a temperature of at least around 80°C for at least around 1 minute.

Where the first material type is a meltable material such as a thermoplastic, the apparatus may further comprise means for melting the wearing elements together into one or more clusters, the means for melting comprising a first heating element, preferably a heated planar surface. The first heating element may be configured to melt only tip regions of the wearing elements, wherein tip regions are regions furthest from an end of the wearing elements at which the wearing elements are coupled to the body. Advantageously, the wearing elements can be melted together by being in contact with or proximity to the first heating element without prematurely heating the body. The first heating element may also be referred to as a wearing element heater or any such equivalent thereof.

Where the second material type is a meltable material such as a thermoplastic, the means for heating may comprise a body heating element for heating the body at least in the region local to the wearing elements, wherein the body heating element heats the body using infrared radiation or hot air. The body heating element may heat at least the region of the body local to the wearing elements to a softening temperature of the second material type of at least 85°C, preferably between around 100°C and 130°C, but no more than 140°C. The softening temperature may be selected to allow the wearing elements to be extracted from the body using a force of less than 100N, preferably less than around 80N or 50N. Preferably softening allows extraction of the wearing elements using a force of around 30N. The force may be defined as the pull force required to remove all of the wearing elements, e.g. all of the bristles. The means for heating may comprise a body soaking element for soaking at least the region of the body local to the wearing elements with a liquid, preferably wherein the liquid is water or an alcoholic solution. The body soaking element may comprise a liquid heating element for heating the liquid to a temperature of at least around 80°C, preferably between 80°C and 100°C, and a bath assembly for completely submerging the region of the body local to the wearing elements in the liquid. The means for soaking may further comprise a liquid covering means for covering the region of the body local to the wearing elements partially or totally with a layer of the liquid, preferably by spraying the liquid.

Where the used consumable item comprises one or more anchors coupled to the wearing elements for securing the wearing elements to the body, the apparatus may further comprise means for separating the one or more anchors from the wearing elements wherein the means for separating is preferably an electrostatic separator, and means for processing the one or more anchors in a third recycling process. Electrostatic separators are readily available equipment.

Where the first material type is a meltable material, the means for processing the wearing elements in the first recycling process may comprise a decontaminator, a shredder, an extruder and a pelletizing apparatus preferably comprising a compressor, a moulder and/or apparatus for sintering. The decontaminator allows any impurities and debris that would otherwise contaminate any recovered materials to be removed.

Where the second material type is a meltable material, the means for processing the body in the second recycling process may comprise a decontaminator, a shredder, an extruder and a pelletizing apparatus preferably comprising a compressor, a moulder and/or apparatus for sintering. Again, the decontaminator allows any impurities and debris that would otherwise contaminate any recovered materials to be removed.

Where at least one of the first material type and the second material type are meltable materials, the means for providing material from at least one of the first and second recycling processes to a process for forming a new consumable item may comprise a melting device, and an injection moulder and/or an extruder.

Any apparatus as described above may be automated, making the recycling of consumable items faster and industrially scalable.

According to another aspect, the present invention provides apparatus for extracting wearing elements from the body of a consumable item, the apparatus comprising: a moveable cradle having a slot, the cradle configured to receive the consumable item and the slot configured to receive the wearing elements; a clamp mechanism configured to clamp the wearing elements; and a heating element configured to heat a region of the body local to the wearing elements.

The cradle and slot can allow the consumable item to be secured in the apparatus by using a friction fit, removing the need for any further securing mechanisms. The heating element can allow the region of the body local to the wearing elements to be softened, facilitating the extraction of the wearing elements from the body.

Thus the wearing elements can be exposed via the slot so that they can be clamped by the clamp mechanism. The cradle may comprise a channel or tunnel for receiving the consumable item. For example, the consumable item may be fed or slotted into the channel, or tunnel. The slot may be formed as a cutaway part of the channel, or tunnel, so that as the consumable item is fed along the channel the wearing elements are received into the slot and exposed for clamping.

The cradle may have a pivot such that when the cradle is rotated about the pivot, the cradle applies a force to the region of the body local to the wearing elements such that the body is moved to separate the body from the wearing elements when the wearing elements are clamped in the clamp mechanism. The pivot can allow a user or actuation device to control the apparatus at a location distant from the heating element and/or the clamp mechanism, reducing the risk of damage or injury.

The heating element may heat the region of the body local to the wearing elements using infra-red radiation. This means the region of the body local to the wearing elements can be heated without contact.

The clamp mechanism and the heating element may be positioned on opposing sides of the cradle. One or both of the clamp mechanism and the heating element may be moveable to allow for movement of the cradle. The clamp mechanism may be movable to allow the wearing elements to be collected, once removed from the body.

The present invention provides a method for extracting wearing elements from the body of a consumable item, the method comprising the steps of: securing the consumable item in a moveable cradle; clamping the wearing elements in a clamp mechanism; softening a region of the body local to the wearing elements; and applying a force to the cradle to move the body to separate the body from the wearing elements.

The cradle may comprise a channel or tunnel for receiving the consumable item. The consumable item may be secured in the moveable cradle by inserting the wearing elements into a slot. The slot may be formed as a cutaway part of the channel or tunnel. Securing the consumable item in the moveable cradle may comprise the step of feeding or slotting the consumable item into the channel, or tunnel, preferably such that the wearing elements are received into the slot and exposed for clamping.

Softening the region of the body local to the wearing elements may comprise the step of heating the region of the body local to the wearing elements. Heating may be achieved using infra-red radiation.

The cradle may have a pivot. Applying a force to the cradle may comprise the step of applying a force, preferably at a location distant from the heating element and/or the clamp mechanism, such that the cradle rotates about the pivot to move the body away from the clamped wearing elements.

The clamp mechanism may be moveable. The method may further comprise the step of moving the clamp mechanism to allow the wearing elements to be collected after the body is separated from the wearing elements.

According to another aspect, the present invention provides a method for supplying consumable items to a user at a supply frequency, the method comprising the steps of: supplying a replacement consumable item and a tracking label for the return of a used consumable item, wherein the tracking label comprises a unique tracking identifier for monitoring a dispatch of the used consumable item; monitoring for dispatch of the used consumable item; correlating the dispatch with the return of the used consumable item; generating a demand prediction for a subsequent replacement consumable item; and adjusting the supply of the subsequent replacement consumable item using the demand prediction.

The method supports the efficient provision of consumable items, providing a flexible supply which can adapt to the demands and usage habits of the user. It also allows supply regimes to be implemented which are adapted to each individual user.

The demand prediction may be generated using previous supply data from supplying at least two replacement consumable items, previous dispatch-return correlations from receiving at least two used consumable items, and/or user feedback. Using these types of data to inform the prediction provides a degree of feedback for the supply process, giving more accurate and stable predictions.

Adjusting the supply may comprise adjusting at least one of the supply frequency, a cost charged to the user, and the number of subsequent replacement consumable items supplied at one time. The replacement consumable item may be formed of recycled material from one or more used consumable items. For example, a supply frequency may be adjusted to be roughly equal to the return (or dispatch) frequency, e.g. equal to the average of the return frequency associated with a plurality preceding dispatches or correlated returns.

The method may further comprise the step of receiving the used consumable item in a packaging bearing the tracking label. The tracking label may be provided on a first or second indicia-bearing surface of a packaging for the consumable item, e.g. packaging as described above. The method may further comprise the steps of recording the supply frequency, and upon not identifying the dispatch of the used consumable item within a predetermined time period after supplying the replacement consumable item, sending a reminder to the user regarding return of the used consumable item.

When the consumable item is a toothbrush or toothbrush head for an electric toothbrush, the predetermined time period may be about 3 months for maintaining good oral hygiene. This encourages prompt return of consumable items and means that users do not need to remember to replace their consumable items regularly. In addition, when using recycled consumable items, monitoring the dispatch and reminding about the return of used consumable items promotes a closed recycling loop, further limiting waste and pollution.

The reminder may be sent via electronic means, such as a message to a communication device of the user, e.g. by email or by a notification in an application on the communication device. The communication device may be a mobile phone or smartphone, tablet or computer, e.g. a PC.

There is also described a method for supplying consumable items to a user, the method comprising the steps of: supplying consumable items to a user in a package containing one or more new consumable items; generating a partial flag on such system as a computer data store for each of the one or more consumable items supplied; updating a flag status associated with the user based on each of the partial flags generated; monitoring for return of one or more used consumable items from the user; and adjusting the flag status associated with the user based on each used consumable item returned from the user.

Preferably, the method further comprises repeating the steps of supplying consumable items to a user in a package containing one or more new consumable items; generating a partial flag for each of the one or more consumable items supplied; and updating the flag status associated with the user based on each of the partial flags generated. The method may further comprise sending a message to the user or adjusting one or more supply parameters for supply of consumable items to the user based on the flag status associated with the user.

The message to the user may comprises one of: a prompt to return items, preferably if the flag status is above a whole flag; advice not to adjust the frequency, preferably if the step of adjusting the flag status is performed in whole flag integers; guidance on adjusting supply frequency, preferably if the return of one or more used consumable items is later than a predicted return time; and a suggestion to delay return of items, preferably if the step of adjusting the flag status is not performed in whole flag integers.

The one or more new consumable items may be supplied in a one-way or a two-way package, selected based on the flag status associated with the user. This encourages the user to return the items efficiently.

Any system feature as described herein may also be provided as a method feature, and vice versa. As used herein, means plus function features may be expressed alternatively in terms of their corresponding structure.

Any feature in one aspect of the invention may be applied to other aspects of the invention, in any appropriate combination. In particular, method aspects may be applied to system aspects, and vice versa. Furthermore, any, some and/or all features in one aspect can be applied to any, some and/or all features in any other aspect, in any appropriate combination.

It should also be appreciated that particular combinations of the various features described and defined in any aspects of the invention can be implemented and/or supplied and/or used independently.

BRIEF DESCRIPTION OF THE FIGURES

Methods and systems for recycling and supplying consumer items are described by way of example only, in relation to the Figures, wherein:

Figure 1a shows an example consumable item from a side view;

Figure 1b shows an example consumable item from a perspective end view;

Figure 2a(i) shows the wearing components of the consumable item of Figures 1a and 1b according to one embodiment from a cross-sectional view;

Figure 2a(ii) shows wearing components attached in an alternative manner to the wearing components of Figure 2a(i); Figure 2a(iii) shows wearing components attached in an alternative manner to the wearing components of Figures 2a(i) and 2a(ii);

Figure 2b shows the wearing components of the consumable item of Figures 1a and 1b according to another embodiment from one cross-sectional view;

Figure 2c shows the wearing components of the consumable item of Figures 2b from a perpendicular cross-sectional view;

Figure 3a shows a schematic diagram of an example method for recovering material from a consumable item;

Figure 3b shows a schematic diagram of another example method for recovering material from a consumable item;

Figure 3c shows a schematic diagram of another example method for recovering material from a consumable item;

Figure 4a shows packaging for transporting a consumable recyclable item from a perspective view;

Figure 4b shows the packaging of Figure 4a for transporting a consumable recyclable item from end views;

Figure 4c shows the packaging of Figure 4a for transporting a consumable recyclable item from a plan view;

Figure 4d shows a cross-section of the packaging of Figure 4b for transporting a consumable recyclable item from the view point 4d shown in Figure 4b;

Figure 4e shows a net diagram of an alternative embodiment of packaging for transporting a consumable recyclable item;

Figure 5a shows a schematic diagram of apparatus for recovering material from consumable items;

Figure 5b shows a schematic diagram of apparatus for forming a new consumable item, partially or wholly from recovered materials;

Figure 5c shows a cross sectional view of an example apparatus for applying heat to used consumable items in order to separate materials;

Figure 5d shows a cutaway view of the example apparatus as a close up image of a clamping detail;

Figure 6a shows a schematic diagram of an example method for supplying consumable items to a user;

Figure 6b shows a schematic diagram of another example method for supplying consumable items to a user; and Figure 7 shows a schematic diagram of another example method for supplying consumable items to a user.

DETAILED DESCRIPTION

Referring to Figures 1a to 3c, example consumable items and a method 100 for recovering material from a consumable item 10 will now be described. The consumable item 10 (shown in Fig. 1 as a toothbrush) comprises wearing elements 20 and a body 30, the body 30 having a region 35 local to the wearing elements 20. The wearing elements 20 are made from a first material type and the body 30 is made from a second material type. In this example, the wearing elements 20 are bristles or filaments made of nylon or polyester, grouped into tufts 25 (shown in Figures 2a-2c) and fixed into holes in the region 35 of the body 30.

According to one embodiment as shown in Fig. 2a(i), the tufts 25 are fixed into the body 30 by melting attachment regions 24 of the wearing elements 20 to other wearing elements 20 and to the body 30. Tip regions 22 of the wearing elements 20 are defined as those furthest from the attachment regions 24, where the wearing elements 20 are coupled to the body 30.

An alternative means for fixing wearing elements to the body 30 is shown in Figure 2a(ii). Tufts 25’ are fixed into the body 30 by inserting attachment regions 24’ of the wearing elements 20 into holes in the region 35’ local to the wearing elements and applying a compacting force to the region 35’ of the body local to the wearing elements in order to crimp the holes against the wearing elements. Tip regions 22’ of the wearing elements 20 are defined as those furthest from the attachment regions 24’. This removes the need for metal anchor wires, thus reducing the number of components and different materials present in the consumable items.

A further alternative means for fixing wearing elements to the body 30 is shown in Figure 2a(iii). The region 35” of the body 30 local to the wearing elements is formed of two different parts, a first part 35a” and a second part 25b”. Tufts 25” are fixed into the body 30 by inserting attachment regions 24” of the wearing elements 20 into holes in the region first part 35a” and melting and/or sealing the ends 24” of the wearing elements. The second part 35b” is then fixed to the first part 35a”, covering the melted/sealed end regions 24” of the wearing elements.

Alternatively, according to a second embodiment as shown in Fig. 2b and 2c, the wearing elements 20 do not require melting in order to be fixed into the body 30. Wearing elements 20 of approximately double the ultimate length of a tuft 25 are gathered together in front of a hole in the body 30, and an anchor 40 is pushed through the midpoint of the wearing elements 20 and on into the hole in the body 30. The anchor 40 is typically a short length of metal anchor wire which is fractionally longer than the diameter of the hole into which the tuft 25 is inserted. As the anchor 40 becomes wedged in the hole, it also captures the midpoint of the wearing elements 20 beneath it, with the wearing elements 20 standing upright out of the hole with their tip regions 22 distant from the anchor 40 to form a single tuft 25. When all the tufts 25 are fitted, they are then trimmed to a uniform length and polished to remove any sharp edges from the cut tip regions 22.

Referring to Fig. 3a, the method 100 first comprises receiving a used consumable item 10a from a user. The wearing elements 20 are made from a first material type and the body 30 is made from a second material type. The wearing elements 20 are fixed into the body 30 using anchors 40 as described above. Upon receipt from the user, the used consumable item 10a may be cleaned and/or disinfected in order to remove debris (such as toothpaste) which would otherwise contaminate any materials recovered.

In a first embodiment shown in Figures 3a and 3b, the method 100 first comprises the step of decontaminating 102 the used consumable item 10a, wherein the used consumable item 10a is washed with water and heated to a temperature of at least around 80°C, for at least around 1 minute. Then the wearing elements 20 are extracted 110 from the body 30. In the particular embodiment shown, in extracting 110 the wearing elements 20 from the body 30, the wearing elements 20 are first clamped 114. Clamping 114 allows the wearing elements 20 to be gathered and collectively manipulated, making the following steps simpler. The wearing elements 20 are clamped by one or by a plurality of clamps. For example, in the case of a brush having a plurality of bristles, there may be a single clamp sized to clamp all of the plurality of bristles. In the alternative, there may be a plurality of clamps, for example one clamp for each tuft 25.

In the method shown, extracting 110 the wearing elements 20 involves the body 30 being softened 116 in order to make the body 30 more pliable for the removal of the wearing elements 20. Softening 116 may occur only in the region 35 of the body 30 local to the wearing elements 20, allowing other parts of the body 30 such as handles, grips and stems to retain structural integrity, e.g. to remain rigid, for subsequent handling of the body 30.

In the case where the second material type is a meltable material, such as a thermoplastic having a lower melting temperature than the first material type (which may also be a thermoplastic, such as nylon), softening 116 is achieved by heating the local region 35 of the body 30. Heat is applied until the second material type reaches a temperature at which it is sufficiently softened without significantly affecting the material state of the wearing elements 20. The softening temperature is preferably at least 85°C, preferably between around 100°C and 130°C, but no more than 140°C. Thus the region of body 30 is preferably heated to predetermined softening temperature, but to less than the melting temperature of the second material. The softening may be performed to soften the body to allow extraction of the wearing elements from the body using a force of less than 100N, preferably less than around 80N or less than around 50N. For example, a force of between around 10N and 40N may be used, or a force of between 20N and 40N may be used. The force is a pull force. Preferably the force allows extraction of all the wearing elements.

Once the body 30 is softened, a force is applied 118 to move the body 30 apart from the clamped wearing elements 20 such that they are completely separated. Only the body 30 or only the wearing elements 20 may be moved to achieve this separation. Alternatively both the body 30 and the wearing elements 20 may be moved. The body 30 is clamped away from the region 35 in a moveable clamp, and then a mechanism engages to apply 118 the force to move the moveable clamp containing the body 30 away from the clamped wearing elements 20 and anchors 40. In other embodiments, the clamp holding the wearing elements 20 may be moveable and the clamp holding the body 30 may remain stationary, or both clamps may be moveable. The body 30 may then be inspected to check that all wearing elements 20 and anchors 40 have been removed. Such inspection may be by a human operator, or may be by a monitoring device. For example, an image may be taken of the body 30 and image or pattern recognition software may be used to check all wearing elements and anchors have been removed.

To recover material from the wearing elements 20, the anchors 40 must be removed. The anchors 40 are made from a non-magnetic metal such as nickel silver (copper alloyed with nickel and zinc), so are separated 120 from the wearing elements 20 using an electrostatic separator. A standard piece of equipment, the electrostatic separator applies an electric charge to the wearing elements 20 and anchors 40, which are typically passed over an oppositely-charged rotating drum to attract the conductive anchors 40 away from the non- conductive wearing elements 20. The separated wearing elements 20 and anchors 40 are then collected and stored or sent for recycling.

The wearing elements 20 are processed 125 in to a first recycling process to produce recovered wearing element material 20’, and the body 30 is processed 130 separately to a second recycling process to produce recovered body material 30’. In this embodiment where both the first and second material types are thermoplastics, as shown in Fig. 3b, the first and second recycling processes comprise the same steps. The wearing elements 20 and the body 30 are decontaminated 132 to further remove any contaminants or traces of other parts of the used consumable item 10a in order to produce purer recovered material 20’, 30’. The wearing elements 20 and body 30 are then shredded 134 to make subsequent handling of the materials easier and reduce their volume. The shredded materials are then pelletized 136 by melting the shredded materials, extruding or moulding them into pellets of recovered materials 20’, 30’, and sintering the pellets.

Although a particular recycling process is shown in Figure 3b, other recycling processes can be used as part of steps 125 and/or 130.

Returning to Figure 3a, following processing 125 the wearing element material in the first recycling process and/or processing 130 the body material in the second recycling process, at least one of the recovered materials 20’, 30’ are passed 140 to a process for forming a new consumable item 10b. The process 140 uses the recovered wearing element material 20’ to form wearing elements of the new consumable item 10b and/or uses the recovered body material 30’ to form the body of the new consumable item 10b. This is achieved by melting the respective pellets and injection moulding or extruding the melted pellets into the shapes of a body and wearing elements. Alternatively, the process 140 receives 122 the wearing elements 20 directly from the separation step 120 to form one or more wearing elements of the new consumable item by melting and extruding the wearing elements 20. Alternatively, recovered body material 30’ may be bio-degraded 135, e.g. through anaerobic digestion to produce natural substances such as methane, which may be used in the production of new material such as PHA, which in turn can be used to form the body of the new consumable item 10b. The new body and wearing elements are attached using new anchor wires, which may be recycled, to form the new consumable item 10b. The new consumable item 10b can be packaged in an inner sleeve held in a container and returned to a user, where the inner sleeve is made from a compostable material such as potato starch or paper.

Referring to Fig. 3c, a method 100’ according for recycling consumable items will now be described. This method 100’ comprises the additional step 105 of melting the wearing elements together performed after the decontamination step 102 and prior to the extraction step 110. The wearing elements 20, again made from a meltable material, are melted or heat welded together within or between the tufts 25 to form one or more clusters. These clusters make the following step of clamping 114 the wearing elements 20 easier and more reliable. Only the tip regions 22 of the wearing elements 20 are melted, for example by brief contact with a heated planar surface. In this embodiment, the second material type is not meltable, such as wood or bamboo. In this case, the step of softening 116 the body 30 is achieved by soaking the body 30 or the region 35 in a liquid with or without the application of heat. The liquid may be water or an alcoholic solution with a concentration of alcohol around 50% v/v, and may be heated to a temperature of at least around 80°C, preferably 100°C. The region 35 local to the wearing elements 20 may be submerged in the liquid in a bath assembly for a predetermined length of time of preferably at least one hour. If an alcoholic solution is used, the region 35 local to the wearing elements 20 may be covered with a layer of the alcoholic solution, for example by spraying the body 30 with the liquid, for a predetermined length of time, wherein the length of time is around one hour, preferably at least around two hours. After the extraction step 110 and before separating 120 the anchors 40 from the wearing elements 20, the one or more clusters are disassembled 115 such that the anchors 40 are not constrained by the wearing elements 20, allowing them to be separated effectively with an electrostatic separator. The clusters can be disassembled 115 such that the melted regions of the wearing elements 20 are completely removed from the melted regions of the wearing elements 20, for example by cutting or snapping the melted regions. Alternatively, the clusters may be disassembled 115 by separating each cluster into its constituent wearing elements 20 or into smaller clusters of wearing elements 20. This may be achieved, for example, by melting and splitting, or mechanically chopping, the clusters.

Furthermore, the second recycling process 130 does not include the steps of shredding 134 and pelletizing 136 the body 30. Instead, after decontaminating 132, the body 30 may be either reused directly for the new consumable item 10b or bio-degraded.

In some examples, after extracting the wearing elements 20 from the body 30, the body 30 is burned or incinerated, preferably for power generation. This allows energy to be recovered from the body 30. In particular, this is particularly advantageous if the body 30 is made from a non-meltable material such as wood or bamboo which is difficult or impossible to recycle. In other examples, the body 30 may be bio-degraded, or simply discarded.

Although in the method of Figure 3a extracting 110 the wearing elements 20 from the body 30 involves the steps of clamping the wearing elements 114, softening the body 116 and applying 118 a force to move the body from the wearing elements, in some methods one or more of these steps may be omitted.

During the step of extracting 110 the wearing elements 20 from the body 30, the body 30 itself may also be clamped (by one or more separate clamps from the clamps used for the wearing elements 20) in order to allow the force to be applied 118.

The step 105, shown in Figure 3c, of melting the wearing elements together may also be performed prior to the extraction step 110 in method 100 shown in Figure 3a and 3b. Referring to Figs. 4a to 4d, packaging 200 for transporting a recyclable consumable item 10 will now be described. The packaging 200 is folded from a single sheet of cardboard, preferably recycled cardboard, and is arranged to hold four consumable items 10 each enclosed in an inner sleeve made from a recyclable and/or compostable material such as potato starch or paper. As shown in Fig. 4a, the packaging 200 has a first indicia-bearing surface 210 disposed on a first hinged flap 220, and a second indicia-bearing surface 230 (on rear surface not shown) disposed on a second hinged flap 240. Further hinged flaps may exist to provide greater structural strength and to create a better seal when the packaging 200 is closed. The packaging 200 when closed has a depth 205 such that the packaging 200 complies with postal regulations. For example, in the United Kingdom it may be beneficial to limit the depth 205 to be no more than 25 mm.

Securing mechanisms 250 are used to secure the consumable items 10 inside the packaging 200 and/or to keep the packaging 200 in a closed state. On each of the hinged flaps 220, 240, there exists securing mechanisms 250 each consisting of a tab 252 and corresponding slots 254 in the other hinged flap 240, 220. Each tab 252 is configured to releasably fit into its corresponding slot 254.

The tabs 252 may each be located within a predetermined distance from the end of the packaging to maintain the depth of the packaging within the selected depth when the packaging is in a closed state. The predetermined distance may be less than around 5cm, or less than around 4cm or 3cm.

In alternative embodiments where there is only a single tab on each flap, the tab may be wide enough such that the edges of the tab are each not more than the predetermined distance from the end of the packaging.

In other embodiments, strips of complementary pieces of adhesive, magnetic, hook- and-loop and/or electrostatic material may be disposed on surfaces of the first hinged flap 220, second hinged flap 240 and/or other surfaces of the packaging 200 as replacement or additional securing mechanisms 250 to those shown in Fig. 4a. Preferably any securing mechanism is reusable, in that it allows securing, unsecuring and resecuring multiple times.

As shown in Fig. 4b, the packaging 200 is arrangeable in a first configuration 200a and a second configuration 200b. In each of the configurations 200a, 200b, the packaging is releasably closed for securing the consumable items 10 and preventing their inadvertent ejection from the packaging 200.

In the first configuration 200a, the hinged flaps 220, 240 are folded in an overlapping manner such that the first hinged flap 220 is uppermost with the first indicia-bearing surface 210 externally visible and the second indicia-bearing surface 230 hidden from any external viewpoint. Each hinged flap 220, 240 does not necessarily span the width of the packaging 200 that the union of the flaps 220, 240 spans. The tabs 252 on the first hinged flap 220 engage with the slots 254 in the second hinged flap 240 to secure the packaging 200 closed. The tabs 252 connected to the second hinged flap 240 may not engage with the slots 254 in the first hinged flap 220.

In the second configuration 200b, the hinged flaps 220, 240 are folded in an overlapping manner such that the second hinged flap 240 is uppermost with the second indicia-bearing surface 230 externally visible and the first indicia-bearing surface 210 hidden from any external viewpoint. The tabs 252 on the second hinged flap 240 engage with the slots 254 in the first hinged flap 220 to secure the packaging 200 closed. The tabs 252 connected to the first hinged flap 220 may not engage with the slots 254 in the second hinged flap 240.

As shown in Fig. 4d, the packaging 200 has slots 260 disposed on internal faces 265, 266 of the packaging 200 for retaining each consumable item 10 within the packaging 200. Each slot 260 receives an end 36 of a consumable item 10 at a face 265 (for the consumable item shown) and the end 38 of the consumable item 10 opposite to the end 36 is held against a substantially opposed internal face 266 with a friction fit.

An alternative embodiment of the packaging 200 is shown in Fig. 4e as a net diagram, wherein each hinged flap 220, 240 has only one tab 252 and one slot 254. Having only one tab 252 makes opening and closing the packaging 200 simpler.

Referring to Figs. 5a to 5d, an apparatus 300 for recovering material from a used consumable item 10a will now be described. The apparatus has a decontaminator 302 comprising a washing element and a heater. The washing element is used to spray, hose or bathe the used consumable item with water. The heater is configured to heat the used consumable item and the water to a temperature of at least around 80°C for at least around 1 minute. The used consumable item 10a is passed to a first heating element 305 which is a heated planar surface for melting the tip regions 22 of the wearing elements 20 together into clusters. Then the used consumable item 10a is passed to means for extracting 310 the wearing elements 20 from the body 30. As shown in Figs. 5c and 5d, the extracting means 310 has a separation mechanism 318 in the form of a channel or cradle, having a slot 311. The used consumable item 10a is inserted into the channel 318 such that the wearing elements are received by the slot 311. The clusters of wearing elements 20 are clamped by a clamping mechanism 312 before the region 35 of the body 30 is softened with softening apparatus 314. The softening apparatus 314 includes a body heating element 316 and/or a body soaking element 317, which are used for softening the body 30 as appropriate according to the second material type. If the second material type is a meltable material, the body heating element 316 heats the region 35 of the body 30 local to the wearing elements 20 to a temperature of at least 85°C, preferably between around 100°C and 130°C, but no more than 140°C. If the second material type is a porous material which softens by soaking, such as wood or bamboo, the body soaking element 317 soaks the region 35 of the body 30 local to the wearing elements 20 for a predetermined length of time in liquid such as water or an alcoholic solution. The body soaking element 317 may comprise a heating element for heating the liquid to a temperature of at least around 80°C, preferably between 80°C and 100°C, a bath assembly for completely submerging the region 35 of the body 30 local to the wearing elements 20 in the liquid, and a liquid covering means for covering at least the region 35 of the body 30 local to the wearing elements 20 partially or totally with a layer of the liquid, preferably by spraying. A separation mechanism 318 is used to move the softened body 30 away from the clamped clusters of wearing elements 20 containing the anchors 40. The separation mechanism includes a moveable clamp or cradle arranged to receive and clamp at least a portion of the body 30 not in the region 35 local to the wearing elements 20. Where the apparatus of Figures 5c and 5d are used, the channel 318, which holds the body 30 is rotated about a pivot 319 to apply a force to the region 35 of the body 30 local to the wearing elements 20 to move the softened body 30 away from the clamped wearing elements 20, to separate the wearing elements 20 from the body 30. Where the wearing elements 20 have been melted into clusters, the separation mechanism may further include means for disassembling the clusters. This may be achieved, for example, with a cutting device which may be used to cut portions of the wearing elements 20 while the clusters are still clamped. In another example, the clusters may be melted and separated into individual wearing elements 20 or smaller clusters thereof.

After separation in the extracting means 310, the wearing elements 20 and the metal anchors 40 are passed to an electrostatic separator 320 for separating the anchors 40 from the wearing elements 20. The electrostatic separator 320 applies an electric charge to the wearing elements 20 and anchors 40 which are both directed across an oppositely-charged rotating drum. The conductive anchors 40 quickly lose their charge to the drum and continue their trajectory unaffected relative to the non-conductive wearing elements 20 which take longer to discharge and so adhere statically to the drum for longer and fall, or are brushed, from it further around the drum’s circumference, allowing the elements 20 and the anchors 40 to be collected in separate locations. The anchors 40 may be passed to a means for processing the anchors 40 in a third recycling process.

The wearing elements 20 are then passed to a first recycling means 330 for processing in a first recycling process. The first recycling means 330 includes a melter 332, an extruder 334 and pelletizing apparatus 336. In the pelletizing apparatus 336, if the first material type is meltable, the shredded material is passed through a compressor 338 and/or a moulder 340 to form pellets. The pellets are then sintered using sintering apparatus 342.

The body 30 is passed to a second recycling means 350 for processing in a second recycling process. The second recycling means 350 includes a shredder 351, melter 352, an extruder354 and pelletizing apparatus 356. In the pelletizing apparatus 356, if the second material type is meltable, the shredded material is passed through a compressor 358 and/or a moulder 360 to form pellets. The pellets are then sintered using sintering apparatus 362.

As shown in Fig. 5b, materials recovered from one or both of the wearing elements 20 and the body 30 using the means for processing 330, 350 respectively are fed to a means for providing material 370 to a process for forming a new consumable item 10b. The means for providing material 370 includes a melting device 372, an injection moulder 374 the body of the new consumable item 10b if the second material type is meltable, and an extruder 376 for reforming the wearing elements of the new consumable item 10b if the first material type is meltable. Although only a single melting device 372 is shown, where both material from the wearing elements and from the body are formed into a new consumable item, these are processed separately in separate melting devices, and each may be melted with virgin material of their respective material types. The means for providing material 370 may also include a digestion apparatus, for digesting anaerobically some or all of the recovered body material 30’. The digestion apparatus captures natural substances such as methane produced by the digestion process, and the natural substances can then be used as a feedstock in the production of new material such as PHA for producing bodies of new consumable items 10b.

The new body and consumable element are assembled with an assembly apparatus 380 which may use new or recycled anchor material to secure the new wearing elements to the new body, thus forming the new consumable item 10b.

All of the above apparatus 300 may be located at a single site, and be configured to provide a fully automated method for recovering material from a used consumable item 10a and producing a new consumable item 10b.

Referring to Fig. 6a, a first embodiment of a method 400 for supplying consumable items 10 to a user will now be described. A replacement consumable item 412 is supplied 410 to a user with a tracking label 414 for the return of a used consumable item 418, the tracking label 414 having a unique tracking identifier 416. The unique tracking identifier 416 is used to monitor 420 a dispatch of a or the used consumable item 418. Upon noting the item has been dispatched by a user, e.g. by use of postal tracking, or upon receiving 460 the used consumable item 418 bearing the tracking label 414, the dispatch is correlated 430 with the return of the used consumable item 418.

A demand prediction is generated 440 using: previous supply data 442 from supplying 410 at least two replacement consumable items 412; previous dispatch-return correlations 444 from receiving 460 at least two used consumable items 418; and/or user feedback 446. The demand prediction can be used as an estimate of the future required quantity and/or timing of supplied replacement consumable items, as well as an estimate of how many used consumable items the user is yet to return.

Using the demand prediction, the supply 410 is adjusted 450, by adjusting at least one of the supply frequency 452, a cost 454 charged to the user, and the number of replacement consumable items 412 supplied 410 in the next delivery. In this method, the replacement consumable items 412 are formed from recycled material recovered from one or more used consumable items 418.

Fig. 6b shows a second embodiment of the method 400, which, in addition to the first embodiment, records 470 the supply frequency measured from the supply step 410. This supply frequency is fed back to the demand prediction generation step 440 and the supply adjustment step 450 to create a feedback loop for the method 400. If, within a predetermined time period after supplying 410, the replacement consumable item 412 a notification of dispatch of a returned used consumable item 418 is not identified, a reminder is sent 480 to the user regarding return of the expected used consumable item 418.

Fig, 7 shows an embodiment of a method 700 for supplying consumable items to a user. The method may be used with any of the consumable items described above. Thus, the method includes receiving a used consumable item returned from the user. This is particularly useful where the consumable items are recyclable, reusable or can be refurbished.

The method 700 starts with an initial step 702 of supplying the consumable item to a user. The step of supplying 702 a consumable item includes providing 704 one or more consumable items. The consumable item is preferably a new consumable item, or could be a refurbished consumable item. Where the user has previously received one or more consumable item, the consumable item provided, or the new or refurbished consumable item, may be referred to as a replacement consumer item. Providing 704 a consumable item may comprise providing multiple consumer items. It may be preferable in terms of cost and/or environmental impact to supply more than one consumable item at a time. The user may also have requested more than one consumable item at a time. For example, for cases where multiple users are located at the same location. Then it may be preferable to supply items for all those users at the same time. Thus, the number of consumer items provided 704 in each supply 702 step may be user-selected. Additionally or alternatively, the number or items dispatched at one time may be selected based on the weight of each item, for example so that the total weight of the items (and the packaging) does not exceed a predetermined weight limit. The weight limit may be, for example, at least 50g or not more than 1kg. In some embodiments the weight limit is between 80g and 200g, for example around 100g. This may allow for multiple items to be dispatched in one package. In some embodiments, items are supplied singly, or individually, e.g. one at a time.

Supplying 702 the consumer item(s) generally includes sending, or transporting, the consumable item(s) to a user’s location. The location may be the user’s abode or place of work. Alternatively, the user’s location may be a local supply point, such as a shop or post office from which the user can collect the item.

Prior to transporting or sending the consumer item to the user, the item is preferably packaged for transit. The packaging may be one-way packaging (intended only for supply of items to the user) or may be two-way packaging (intended for both supply of the new item to the user and return of the used item by the user). For example, the item may be packaged using the two-way packaging described above.

The step of supplying 702 the consumable item also comprises providing 706 supply information for dispatch or supply of the one or more consumable item(s) to the user, e.g. by making the information visible on the packaging. The supply information can be used to ensure the item is delivered to the user’s location. For example, the supply information can contain the user’s name and address of their location. The supply information may also contain a unique tracking identifier. The supply tracking identifier may be indicative of the particular consumable item supplied and/or the user. The supply tracking identifier may additionally or alternatively be indicative of the date of dispatch of the consumable item from the supplier. The supply tracking identifier may be linked, e.g. in a mapping table, to the user and/or date of dispatch in a data store in step 706. The supply tracking identifier may also be indicative of the number of items supplied.

In some embodiments step 702 also comprises providing return information, such as the address of a site of the supplier of consumable items, which may comprise a warehouse or store of consumable items, or of a site with a recycling facility or refurbishing facility for the consumable items. In some cases, consumable items may be supplied from the same site at which they are recycled or refurbished. The return information may also include a unique identifier, such as a return tracking identifier. The unique return tracking identifier may be the same as or different from the unique identifier used for the supply tracking identifier. Preferably the return tracking identifier is linked, e.g. in a mapping table, to at least the user in step 706.

In preferred embodiments the step of supplying 702 the consumable item(s) also comprises providing 706 a tracking label bearing the supply information for the one or more consumable items. Step 706 may comprise fixing the tracking label to the packaging for the consumable item, e.g. by adhesive. Where return information is provided, a return tracking label may also be provided. For example, the return tracking label may be provided within the packaging, but not fixed to the packaging, in step 706, so that a user can affix the return label to the packaging prior to returning the item. Thus the return tracking label can be affixed to the packaging so the same packaging can be used for the supply and return trips.

In some embodiments two-way packaging is used which has different configurations for displaying different information at different times, such as a first configuration in which a first indicia-bearing surface of the packaging is visible and a second indicia-bearing surface of the packaging is hidden from view and a second configuration in which the first indicia bearing surface is hidden from view and the second indicia-bearing surface is visible. For example packaging substantially as discussed above may be used. In such cases step 706 may comprise fixing a return tracking label to packaging, e.g. by adhesive.

In alternative embodiments, no tracking labels are provided and instead the supply and/or return information is printed directly onto the packaging. For example, the supply information is printed on the first indicia-bearing surface and the return information is printed on the second indicia-bearing surface of two-way packaging.

As mentioned above, step 702 comprises sending, or dispatching, the consumable item(s) to the user, or to the user’s location. For example this can be done via a transporting means such as a postal or courier service. The transporting means can provide tracking of the item(s), e.g. via a unique identifier (optionally via the supply or return identifiers described above). Thus the date (and optionally the time) a package of consumable item(s) leaves the supplier and the date (and optionally the time) the package reaches the user’s location may be monitored and reported to the supplier. Date (and optionally time) of arrival and/or departure of one or more intermediate points along the way may also be monitored.

As touched upon above, the supply step 702 may include updating a supply data store relating to supply of the consumable items. The data store comprises information related to each user supplied, for example the user’s name and address. Billing information for the user may also be stored. For each user, a supply frequency is also stored in the supply data store. The supply frequency may, for example, take the form of a number of items per unit time, e.g. four items per year, or 1 item per month. Instead of (or in addition to) a supply frequency, the data store could comprise a supply interval for the user, such as in the form of the time between supply of items, e.g. two months between consecutively supplied items, or 3 weeks between consecutively supplied items. As can be understood, a supply frequency can be converted to a supply interval, e.g. three items per year is equivalent to one item every four months.

When the one or more item(s) are sent, or dispatched, in step 702, the tracking information provided to the item(s) is linked to the user in the data store. The date, and optionally the time, of dispatch can also be linked to the supply tracking identifier, and thus directly or indirectly to the user. Thus the data store can be updated to record the number of items supplied to a user on a certain date. Preferably, where the return tracking identifier is different from the supply tracking identifier, the return tracking identifier is linked in the data store either directly to the user, or indirectly to the user, e.g. by linking to the supply tracking identifier. Again, the link may be in the form of a mapping table.

Upon sending the one or more consumable item(s) to the user in step 702, a partial flag is generated in the data store and linked to the user in step 720. The partial flag is indicative of the number of items dispatched to the user. The partial flag may be calculated such that a whole, or complete flag, is equal to an optimal number of items to be returned by a user at once. The optimal number may be an optimal number for efficiency and/or for lowering the environmental impact. The optimal number of items may be selected based on the weight of the consumable item. For example the optimal number can be chosen so that the optimal number of items is the greatest number of items for which the total weight of the optimal number of items (and the packaging) does not exceed a predetermined weight limit. The weight limit may be, for example, at least 50g or not more than 1kg. In some embodiments the weight limit is between around 80g and 200g, for example around 100g.

Step 720 comprises adding the partial flag generated to any flag, or partial flag, already associated with the user in the supply data store and updating the flag or partial flag associated with the user in the data store.

Step 730 comprises receiving one or more used consumable items from a user, preferably in a single package. Preferably the package displays the return tracking information that was sent in a supply package to the user, as discussed above. Step 730 may thus further comprise tracking the return of one or more used consumable items from a user. For example, when a user sends or dispatches a package of one or more used consumable items, bearing return tracking information, this may be monitored by the supplier or recycling/refurbishing party. For example, a notification indicative of the date and optionally the time and/or location of dispatch may be sent to the supplier or recycling/refurbishing party. The notification may also include the weight of the return package. From the weight, the number of consumable items can be determined when the items are dispatched for return by the user. This information may be entered into the supply data store, or into a separate return data store. Thus the dispatch of the return package comprising one or more used consumable items may be linked to the user, e.g. by identification of the user from the return information and linking to the user in the supply data store.

In other embodiments, the number of consumable items may not be determined in step 730 until the return package arrives at the intended destination, e.g. the location of the supplier or recycler or refurbishing party. For example, the consumable items may be counted, or weighed and then the number determined, upon receipt of the package. This can be linked to the user by use of the unique identifier, e.g. supply or return tracking identifier. Alternatively, it may be linked to the user because the user’s details (e.g. name and/or address) are still displayed on the packaging, e.g. a face of the packaging that is not visible when arranged for return.

Step 740 comprises correlating actual return of items received in step 730 with an anticipated return of the consumable items. The anticipated return may be based on the supply frequency, discussed above. Correlation can be done by generating a partial flag for each item in the return package and adjusting the flag status associated with the user in the supply data store based on the partial flag generated. Such adjustment can be in the opposite direction from that in step 720, e.g. so that the flag status is reduced for each item received.

At step 750, user communication is provided based on input from steps 720 and/or 740. The user communication may be in the form of a written communication, e.g. via letter, or in electronic communication, e.g. to a device associated with the user such as a mobile telephone or personal computer or tablet, e.g. via email or text message or via an application.

For example, step 750 can comprise prompting 760 the user to return items. Prompting 760 the user to return items can be based on the flag associated with the user in the supply data store. For example the flag reaching or exceeding a whole flag number may trigger a prompt to the user. Alternatively or additionally, the flag being equal to or exceeding a whole flag for more than a predetermined time period may trigger prompting 760.

Step 750 can comprise sending 762 a message thanking the user for their return and suggesting no change to the supply frequency, for example if the anticipated return is equal to, or within a predetermined limit of, the actual return.

Step 750 can comprise sending 764 a message offering guidance on adjusting the supply frequency if the return is later than expected.

Step 750 can comprise sending 766 a message encouraging the user to wait longer before returning items if the consumable items received at step 730 were fewer than the optimal number (e.g. if the negative flag adjustment made at step 740 was less than a whole flag).

In some embodiments the flag generated in steps 720 and 730 and adjusted in step 740 may be used to determine what type of packaging to use in supplying the items in step 702. Thus step 702 can comprise determining whether to use one-way or two-way packaging based on the flag status. If the flag status for the user is less than a whole flag, one-way packaging may be used. Whereas if the flag status for the user is at least or more than a whole flag, two-way packaging may be used, preferably with return information provided. This may encourage optimal return of items.

Thus a method may comprise supplying 702 multiple packages of one or more new consumable items to a user in one-way packaging, updating 720 the flag status for a user upon sending each package, and upon determining the flag status for the user is at least a whole flag, sending one or more new consumable items to a user in two-way packaging. While a specific processes and apparatus are shown, any appropriate hardware or software architecture may be employed. For example, communication with a user may be via the internet.

The above embodiments and examples are to be understood as illustrative examples. Further embodiments, aspects or examples are envisaged. It is to be understood that any feature described in relation to any one embodiment, aspect or example may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, aspects or examples, or any combination of any other of the embodiments, aspects or examples. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims. Aspects of the methods and apparatus described herein are further exemplified in the following numbered CLAUSES:

1. A method of recovering material from a used consumable item comprising one or more wearing elements made from a first material type and a body made from a second material type, the method comprising the steps of: extracting the wearing elements from the body; processing the wearing elements in a first recycling process; processing the body in a second recycling process; and providing material from at least one of the first and second recycling processes to a process for forming a new consumable item.

2. The method according to any preceding clause, wherein the wearing elements comprise a plurality of bristles.

3. The method according to any preceding clause, wherein the body comprises a handle.

4. The method according to any preceding clause, wherein the used consumable item (and preferably the new consumable item) is a toothbrush, or a toothbrush head for use with an electric toothbrush.

5. The method according to any preceding clause, wherein extracting the wearing elements from the body comprises the steps of: clamping the wearing elements; softening the body at least in a region local to the wearing elements; and applying a force to move the body and/or the wearing elements to separate the body from the wearing elements.

6. The method according to any preceding clause, wherein: the wearing elements are made entirely from the first material type; and the body is made entirely from the second material type.

7. The method according to any preceding clause, wherein the second material type comprises a mixture of two or more materials.

8. The method according to any preceding clause, wherein a major portion of the wearing element material from the first recycling process and/or a major portion of the body material from the second recycling process are provided directly to the process for forming a new consumable item.

9. The method according to any preceding clause, wherein the first material type is a meltable material, such as a thermoplastic. 9a. The method according to any preceding clause, wherein at least one of the first material type and the second material type is a meltable material, such as a thermoplastic; and preferably wherein the first material type has a higher melting temperature than the second material type.

9b. The method according to clause 9a, further comprising the step of: melting the wearing elements together into one or more clusters prior to extracting the wearing elements from the body, preferably wherein melting the wearing elements together comprises the step of: melting only tip regions of the wearing elements, wherein tip regions are regions furthest from an end of wearing elements at which the wearing elements are coupled to the body.

10. The method according to any preceding clause, wherein the first material type is a polymer, preferably nylon or polyester.

11. The method according to clauses 9 or 10 as dependent on clause 9, further comprising the step of: melting the wearing elements together into one or more clusters prior to extracting the wearing elements from the body.

12. The method according to clause 11, wherein melting the wearing elements together comprises the step of: melting only tip regions of the wearing elements, wherein tip regions are regions furthest from an end of wearing elements at which the wearing elements are coupled to the body.

13. The method according to any preceding clause, wherein the second material type is a meltable material, such as a thermoplastic.

14. The method according to any preceding clause, wherein the second material type is a polymer, preferably polyhydroxyalkanoate, PHA.

15. The method according to clauses 7 and 14 or any clauses dependent thereon, wherein the second material type comprises a composite blend of two or more polymers, preferably polybutylene succinate, PBS, and a polyhydroxyalkanoate, PHA such as poly(3-hydroxybutyrate-co-3-hydroxyvalerate), PHBV.

15a. The method according to any preceding clause, wherein the second material type is a polymer, preferably polyhydroxyalkanoate, PHA, preferably wherein the second material type comprises a composite blend of two or more polymers, preferably polybutylene succinate, PBS, and a polyhydroxyalkanoate, PHA such as poly(3-hydroxybutyrate-co-3- hydroxy valerate), PHBV.

16. The method according to clauses 10 and 14 or any clauses dependent thereon, wherein the first material type has a higher melting temperature than the second material type.

17. The method according to clause 16 as dependent on clause 5 or any clause dependent on clause 5, wherein softening the body comprises the step of applying heat until at least the region local to the wearing elements reaches a temperature of at least 85°C, preferably between around 100°C and 130°C, but no more than 140°C.

18. The method according to any of clauses 1 to 12, wherein the second material type is wood or bamboo.

19. The method according to clause 18 as dependent on clause 5 or any clause dependent on clause 5, wherein softening the body comprises the step of soaking at least the region local to the wearing elements in a liquid preferably heated to a temperature of at least around 80°C, preferably between 80°C and 100°C; wherein the liquid is preferably water or an alcoholic solution preferably with an alcohol concentration of around 50% v/v .

20. The method according to any preceding clause, wherein at least one of the first material type and the second material type is bio-degradable at ambient temperatures and/or under anaerobic conditions.

21. The method according to any preceding clause, wherein the used consumable item comprises: one or more anchors coupled to the wearing elements for securing the wearing elements to the body; wherein the method further comprises: separating the anchors from the wearing elements.

21a. The method according to clause 21 and clause 9b or any claim dependent thereon, further comprising the step of: disassembling the one or more clusters prior to separating the anchors from the wearing elements; wherein disassembling preferably comprises cutting at least a portion of the wearing elements.

21b. The method according to clause 21 or 21a, wherein the anchors are made of metal, preferably a copper alloy such as nickel silver, preferably wherein separating the anchors from the wearing elements comprises the step of electrostatically separating the anchors from the wearing elements. 22. The method according to clause 21, wherein the anchors are made of metal, preferably a copper alloy such as nickel silver.

23. The method according to clause 22, wherein separating the anchors from the wearing elements comprises the step of electrostatically separating the anchors from the wearing elements.

24. The method according to any preceding clause, further comprising the step of: decontaminating the used consumable item prior to extracting the wearing elements from the body, wherein the used consumable item is washed with a washing agent, preferably water, and the used consumable item is heated at a temperature of at least around 80°C, for at least around 1 minute.

25. The method according to clause 9 or any clause dependent thereon, wherein the first recycling process comprises the steps of: melting the wearing elements; extruding the melted material from the melted wearing elements; and pelletizing the extruded material from the extruded, melted wearing elements.

26. The method according to clause 13 or any clause dependent thereon, wherein the second recycling process comprises the steps of: shredding the body; melting the shredded body material; extruding the melted body material; and pelletizing the extruded body material.

27. The method according to any preceding clause, wherein the process for forming a new consumable item comprises the steps of: using material recovered by the first recycling process to form one or more wearing elements of the new consumable item, preferably by melting and extruding; and/or using material recovered by the second recycling process to form a body of the new consumable item, preferably by melting and injection moulding.

28. The method according to clauses 15 and 27 or any clauses dependent thereon, wherein the material recovered by the second recycling process comprises a composite blend of the two or more polymers.

29. The method according to clause 27 or 28, wherein the material recovered by the second recycling process is mixed with virgin material of the second material type to form the body of the new consumable item. 30. The method according to any of clauses 27 to 29, wherein the material recovered by the first recycling process is mixed with virgin material of the first material type to form the wearing elements of the new consumable item.

31. The method according to any preceding clause, further comprising the step of: receiving the used consumable item from a user.

32. The method according to any preceding clause, further comprising the step of: returning the new consumable item to a user.

33. The method according to clause 32, wherein the new consumable item is packaged in an inner sleeve held in a container, wherein the inner sleeve is recyclable and/or compostable.

34. The method according to any preceding clause, wherein the process for forming a new consumable item is performed at the same site as at least one of the first and second recycling processes, preferably in a substantially continuous process.

35. The method according to any preceding clause, wherein the method is performed at a single site, preferably in a substantially continuous process.

35a. The method according to any preceding clause, wherein the process for forming a new consumable item is performed at the same site as at least one of the first and second recycling processes, preferably in a substantially continuous process; and/or wherein the method is performed at a single site, preferably in a substantially continuous process.

36. Packaging for transporting a new or used consumable, recyclable item, wherein: the packaging is arrangeable in a first configuration and a second configuration; wherein in each of the first configuration and the second configuration the packaging is releasably closed for securing the new or used consumable item inside the packaging; wherein in the first configuration a first indicia-bearing surface of the packaging is visible and a second indicia-bearing surface of the packaging is hidden from view; and wherein in the second configuration the first indicia-bearing surface is hidden from view and the second indicia-bearing surface is visible.

36a. Packaging for transporting a new or used consumable, recyclable item, wherein: the packaging is arrangeable in a first configuration and a second configuration; wherein in each of the first configuration and the second configuration the packaging is releasably closed for securing the new or used consumable item inside the packaging; wherein in the first configuration a first indicia-bearing surface of the packaging is visible and a second indicia-bearing surface of the packaging is hidden from view; wherein in the second configuration the first indicia-bearing surface is hidden from view and the second indicia-bearing surface is visible; and preferably wherein the packaging is arranged to hold more than one consumable item, more preferably at least four consumable items.

37. The packaging according to clause 36, wherein the packaging is made from cardboard, preferably recycled cardboard.

38. The packaging according to clauses 36 or 37, wherein the packaging is arranged to hold more than one consumable item, preferably at least four consumable items.

39. The packaging according to any of clauses 36 to 38, wherein: a first hinged flap is arranged uppermost in the first configuration; and a second hinged flap is arranged uppermost in the second configuration; wherein in each of the first configuration and second configuration the first hinged flap and the second hinged flap overlap.

40. The packaging according to any of clauses 36 to 39, further comprising: one or more retaining features for retaining the or each new or used consumable item inside the packaging.

41. The packaging according to clause 40, wherein the or each retaining feature comprises: a slot for receiving an end of the consumable item; wherein the slot is disposed in an internal face of the packaging; and wherein an end of the consumable item opposite to the end received in the slot is held against a second internal face of the packaging with a friction fit, wherein the two internal faces are substantially opposed.

42. The packaging according to any of clauses 36 to 41 , further comprising: a first securing mechanism for keeping the packaging closed in the first configuration; and a second securing mechanism for keeping the packaging closed in the second configuration.

43. The packaging according to clause 40 or 42, wherein at least one of the securing mechanisms comprises: one or more tabs; and one or more slots; wherein at least one of the tabs is configured to releasably fit into at least one of the slots.

43a. The packaging according to clause 36a, wherein: a first hinged flap is arranged uppermost in the first configuration; and a second hinged flap is arranged uppermost in the second configuration; wherein in each of the first configuration and second configuration the first hinged flap and the second hinged flap overlap; and preferably wherein the packaging further comprises: a first securing mechanism for keeping the packaging closed in the first configuration; and a second securing mechanism for keeping the packaging closed in the second configuration; preferably wherein at least one of the securing mechanisms comprises one or more tabs and one or more slots, wherein at least one of the tabs is configured to releasably fit into at least one of the slots.

43b. The packaging according to clause 36a or 43a, further comprising one or more retaining features for retaining the or each new or used consumable item inside the packaging, preferably wherein the or each retaining feature comprises: a slot for receiving an end of the consumable item; wherein the slot is disposed in an internal face of the packaging; and wherein an end of the consumable item opposite to the end received in the slot is held against a second internal face of the packaging with a friction fit, wherein the two internal faces are substantially opposed.

44. The packaging according to any of clauses 40 to 43, wherein at least one of the securing mechanisms comprises: one or more tabs for operating at least one of the securing mechanisms.

45. The packaging according to any of clauses 40 to 44, wherein the securing mechanisms operate via mechanical, adhesive, magnetic, hook-and-loop and/or electrostatic means.

46. The packaging according to any of clauses 36 to 45, wherein the packaging is constructed by folding a single sheet of material.

47. The packaging according to any of clauses 36 to 46, wherein the or each new consumable item is individually enclosed in an inner sleeve, wherein the or each inner sleeve is recyclable and/or compostable, and wherein the inner sleeve is contained in the packaging.

48. Apparatus for recovering material from a used consumable item having one or more wearing elements made from a first material type and a body made from a second material type, the apparatus comprising: means for extracting the wearing elements from the body; means for processing the wearing elements in a first recycling process; means for processing the body in a second recycling process; and means for providing material from at least one of the first and second recycling processes to a process for forming a new consumable item.

49. The apparatus according to clause 48, wherein the means for extracting the wearing elements from the body comprises: a clamping mechanism configured to receive the wearing elements; softening apparatus for softening the body at least in a region local to the wearing elements; and a separation mechanism operable to apply a force to move the body and/or the wearing elements to separate the body from the wearing elements.

50. The apparatus according to clauses 48 or 49, wherein the first material type is a meltable material such as a thermoplastic, the apparatus further comprising: means for melting the wearing elements together into one or more clusters, the means for melting comprising a first heating element, preferably a heated planar surface.

51. The apparatus according to clause 50, wherein the first heating element is configured to melt only tip regions of the wearing elements, wherein tip regions are regions furthest from an end of the wearing elements at which the wearing elements are coupled to the body.

52. The apparatus according to clause 49 or any clause dependent thereon, wherein the second material type is a meltable material such as a thermoplastic, the softening apparatus comprising: a body heating element for heating the body at least in the region local to the wearing elements; preferably wherein the body heating element heats the body using infrared radiation or hot air.

53. The apparatus according to clause 52, wherein the body heating element heats at least the region of the body local to the wearing elements to a temperature of at least 85°C, preferably between around 100°C and 130°C, but no more than 140°C. 54. The apparatus according to any of clauses 49 to 51, wherein the means for heating comprises a body soaking element for soaking at least the region of the body local to the wearing elements with a liquid, the body soaking element comprising: a liquid heating element for heating the liquid to a temperature of at least around 80°C, preferably between 80°C and 100°C; and a bath assembly for completely submerging the region of the body local to the wearing elements in the liquid.

55. The apparatus according to any of clauses 48 to 54, wherein the used consumable item comprises one or more anchors coupled to the wearing elements for securing the wearing elements to the body, and wherein the apparatus further comprises: means for separating the one or more anchors from the wearing elements, wherein the means for separating is preferably an electrostatic separator; and means for processing the one or more anchors in a third recycling process.

56. The apparatus according to any of clauses 48 to 55, wherein the first material type is a meltable material and wherein the means for processing the wearing elements in the first recycling process comprises: a melter; an extruder; and a pelletizing apparatus, preferably comprising a compressor, a moulder and/or apparatus for sintering.

57. The apparatus according to any of clauses 48 to 56, wherein the second material type is a meltable material and wherein the means for processing the body in the second recycling process comprises: a shredder; a melter; an extruder; and a pelletizing apparatus, preferably comprising a compressor, a moulder and/or apparatus for sintering.

58. The apparatus according to any of clauses 48 to 57, wherein at least one of the first material type and the second material type are meltable materials and wherein the means for providing material from at least one of the first and second recycling processes to a process for forming a new consumable item comprises: a melting device; and an injection moulder and/or an extruder. 59. The apparatus according to any of clauses 48 to 57, wherein the apparatus is automated.

60. A method for supplying consumable items to a user at a supply frequency, the method comprising the steps of: supplying a replacement consumable item and a tracking label for the return of a used consumable item, wherein the tracking label comprises a unique tracking identifier for monitoring a dispatch of the used consumable item; monitoring for dispatch of the used consumable item; correlating the dispatch with the return of the used consumable item; generating a demand prediction for a subsequent replacement consumable item; and adjusting the supply of the subsequent replacement consumable item using the demand prediction.

61. The method according to clause 60, wherein the demand prediction is generated using previous supply data from supplying at least two replacement consumable items; previous dispatch-return correlations from receiving at least two used consumable items, and/or user feedback.

62. The method according to clause 60 or 61, wherein adjusting the supply comprises adjusting at least one of the supply frequency, a cost charged to the user, and the number of subsequent replacement consumable items supplied.

63. The method according to any of clauses 60 to 62, wherein the replacement consumable item is formed of recycled material from one or more used consumable items.

64. The method according to any of clauses 60 to 63, further comprising the step of: receiving the used consumable item in a packaging bearing the tracking label.

65. The method according to any of clauses 60 to 63, further comprising the steps of: recording the supply frequency; and upon not identifying the dispatch of the used consumable item within a predetermined time period after supplying the replacement consumable item, sending a reminder to the user regarding return of the used consumable item.

66. A method for supplying consumable items to a user, the method comprising the steps of: supplying consumable items to a user in a package containing one or more new consumable items; generating a partial flag for each of the one or more consumable items supplied; updating a flag status associated with the user based on each of the partial flags generated; monitoring for return of one or more used consumable items from the user; and adjusting the flag status associated with the user based on each used consumable item returned from the user.

67. A method according to clause 66, further comprising repeating the steps of: supplying consumable items to a user in a package containing one or more new consumable items; generating a partial flag for each of the one or more consumable items supplied; and updating the flag status associated with the user based on each of the partial flags generated.

68. A method according to clause 66 or 67, further comprising: sending a message to the user or adjusting one or more supply parameters for supply of consumable items to the user based on the flag status associated with the user.

69. A method according to clause 68, wherein the message to the user comprises one of: a prompt to return items, preferably if the flag status is above a whole flag; advice not to adjust the frequency, preferably if the step of adjusting the flag status is performed in whole flag integers; guidance on adjusting supply frequency, preferably if the return of one or more used consumable items is later than a predicted return time; a suggestion to delay return of items, preferably if the step of adjusting the flag status is not performed in whole flag integers.

70. A method according to any of clauses 66 to 69, wherein the one or more new consumable items are supplied in a one-way or a two-way package, selected based on the flag status associated with the user.

71. A method according to any of clauses 66 to 70, wherein the partial flag generated for each item is selected such that the total flag adjustment for an optimal number of items returned in one package is a whole flag.

72. Apparatus for extracting wearing elements from the body of a consumable item, the apparatus comprising: a moveable cradle having a slot, the cradle configured to receive the consumable item and the slot configured to capture receive the wearing elements; a clamp mechanism configured to clamp the wearing elements; and a heating element configured to heat a region of the body local to the wearing elements.

73. The apparatus according to clause 72, wherein the cradle has a pivot such that when the cradle is rotated about the pivot, the cradle applies a force to the region of the body local to the wearing elements such that the body is moved to separate the body from the wearing elements when the wearing elements are clamped in the clamp mechanism.

74. The apparatus according to clauses 72 or 73, wherein the heating element heats the region of the body local to the wearing elements using infra-red radiation.

75. A method for extracting wearing elements from the body of a consumable item, the method comprising the steps of: securing the consumable item in a moveable cradle; clamping the wearing elements in a clamp mechanism; softening a region of the body local to the wearing elements; and applying a force to the cradle to move the body to separate the body from the wearing elements.

76. The method according to clause 75, wherein the consumable item may be secured in the moveable cradle by inserting the wearing elements into a slot.

77. The method according to clause 76, wherein securing the consumable item in the moveable cradle comprises the step of: feeding or slotting the consumable item into the channel, or tunnel, preferably such that the wearing elements are received into the slot and exposed for clamping.

78. The method according to clause 75 or any clause dependent thereon, wherein softening the region of the body local to the wearing elements comprises the step of: heating the region of the body local to the wearing elements, preferably using infrared radiation.

79. The method according to clause 75 or any clause dependent thereon, wherein the cradle has a pivot, and wherein applying a force to the cradle comprises the step of: applying a force, preferably at a location distant from the heating element and/or the clamp mechanism, such that the cradle rotates about the pivot to move the body away from the clamped wearing elements.

80. The method according to clause 75 or any clause dependent thereon, wherein the clamp mechanism is moveable, wherein the method further comprises the step of: moving the clamp mechanism to allow the wearing elements to be collected after the body is separated from the wearing elements.

81. A computer-readable medium comprising instructions which, when executed by a computer, cause the computer to carry out the method of any preceding method clause.